Apparatus and method for producing building boards



Sept. 28, 1954 F. M. LENG 2,689,975

APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 18 Sheets-Sheet 1 ATTORNEY Sept. 28, 1954 F. M. LENG 2,689,975

APPARATUS AND uz'mop FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 1s Sheets-Sheet 2 FRANZ MAR/A4 'ZEAQ;

ATTORNEY Sept. 28, 1954 F M. LENG 2,639,975

APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 18 Sheets-Sheet 3 ATTORNEY Sept. 28, 1954 F. M. LENG 2,689,975

APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 18 Sheets-Sheet 4 INVENTOR F. M. LENG Sept. 28, 1954 APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 18 Sheets-Sheet 5 ATTORNEY p 1954 F. M. LENG 2,689,975

APPARATUS AND METHOD FOR PRODUCING BUILDINGVBOARDS Filed Jan. 15, 1952 18 Sheets-Sheet 6 ATTORNEY Sept. 28, 1954 F. M. LENG 2,639,975

APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 l8 Sheets-Sheet 7 BY l /%W A 1% 2 Sept. 28, 1954 F. M. LENG 2,689,975

APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 18 Sheets-Sheet 8 25 @Qgl f"\ L n I FL 5 L "EL t: nk cu: g :LA I I 5 I l l 65 g I g I i I I l I u m1: at a: i=1: an =1: m =r= a P A u 1 INVENTOR.

14 TTOR/Vf) Sept. 28, I954 F, LENG 2,689,975

APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 Y 18 Sheets-Sheet 9 Sept. 28, 1954 F. M. LENG 2,689,975

APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 1'8 Sheets-Sheet l0 Sept. 28, 1954 F. M. LENG 2,689,975

APPARATUS AND METHOD FOR PRODUQING BUILDING BOARDS Filed Jan. 15, 1952 I 18 Sheets-Sheet 11 lea IN VEN TOR. FRANZ MAP/A (ENG ATTORNEY Sept. 28, 1954 F. M. LENG APPARATUS AND METHOD FOR PRODUCING BUILDING, BOARDS 18 Sheets-Sheet 12 Filed Jan. 15, 1952 3: 2:. T INVENTOR.

' fR/I/VZ MAE/4 LEA/G BY 1\\ \\\\\X\ 1 m I 1 ATTORNEY I I \J 'F. M. LENG Sept. 28, 1954 APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS l8 Sheets-Sheet 15 Filed Jan. 15, 1952 INVENTOR. FRANZ 014mm AENG A TTO/P/VEY F. M. LENG Sept. 28, 1954 APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS I8 Sheets-Sheet 14 Filed Jan. 15, 1952 INVENTOR. FRANZ MAI/P44 ZE/VG Sept. 28, 1954 M LENG 2,689,975

APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 18 Sheets-Sheet l5 ATTORNEY Sept. 28, 1954 F. M. LENG 2,639,975

APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 1s Sheets-Sheet 1e mam,

H TTOKIVE) Sept. 28, 1954 F. M. LENG APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 18 Sheets-Sheet 17 1477 ORA/E Y Sept. 28, 1954 F. M. LENG 2,689,975

3 APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS Filed Jan. 15, 1952 18 Sheets-Sheet 18 L. 39 57 M m 59 I N V EN TOR. FRANZ M46 64 Zf/VG Patented Sept. 28, 1954 STATES ATENT OFFICE APPARATUS AND METHOD FOR PRODUCING BUILDING BOARDS 9 Claims.

The present invention relates to new and improved apparatus and method for producing building boards from wood wool, excelsior or similar vegetable fiber material in the form of elongated, elastically resilient, crooked strands, and a suitable binding agent such as Portland cement. For convenience of expression, the fiber material is herein referred generically as wood wool or excelsior.

The present application is a continuation-inpart of my copending application, Serial No. 97,178, filed June 4, 1949.

It is an object of the present invention to provide a continuous production line process for making uniform, high quality building boards from excelsior and, a binding agent. The product produced in accordance with the present invention is characterized by uniformity of density and strength and by a high strength-density ratio. The bending strength about an axis transverse to the longitudinal axis of the building board is especially high. A further characteristic of the product is that the edges are straight and strong. While the density of the board is otherwise uniform throughout its area, the marginal portions become progressively denser toward the edges and the percentage of voids in the material progressively decreases so that the edges are firm and strong. The number of contacts between individual strands in the material is greater in the marginal portion, thereby providing still greater strength. At the edges, the strands are bent sharply so that one portion of a strand lies approximately in, or parallel to, one face of the board while another portion of the same strand lies approximately in, or parallel to, the edge surface of the board, for example at right angles to the first portion. The edges of the board are sharply defined and may be either square or otherwise shaped, as desired, for example to provide tongue-and-groove, shiplap or V-shaped edges.

Another object of the invention is to provide a process for making high quality building boards in a practical and economical manner. In accordance with the invention, there is a continuous flow of the material from the initial preparation of the excelsior to the finished building board. The excelsior is cut to predetermined lengths, moistened, preferably with a chemical solution, and coated with a binding agent by blowing the binder in dry powedered form into a tumbling mass of the wet fiber. The coated fiber is then strewn or scattered uniformly onto a moving train of rectangular pressing plates to deposit a layer of material on the plates and the deposited material is combed to level the layer and orient individual pieces of material so as to lie approximately in the direction of movement of the plates. The material is confined on the plates so as to leave a peripheral marginal portion of each plate substantially free of material. After a preliminary compacting of the material, for example by means of rollers, the plates are stacked in superposed relationship with the layers of material therebetween. Edge-pressing strips are positioned between the marginal portions of the plates and pressure is applied to the plates and to the edge-pressing strips so as to compress the material in a direction perpendicular to the plates and also in a direction parallel to the plates. The pressing of the material, like the preparation of the material and the depositing of the material on the pressing plates, is preferably efiected in a continuous manner to provide a high rate of production at low cost.

A further object Of the invention is to provide compact, economical and efficient apparatus for carrying out the aforementioned process. The apparatus permits continuous operation and is, for the most part, automatic, reducing to a minimum the man-hours required in the production of the wall boards.

The objects and advantages of the invention will be more fully understood from the following description in conjunction with the accompanying drawings which show, by way of example, apparatus for carrying out the process.

In the drawings:

Fig. 1 is a schematic elevation, partly in section of a plant for carrying out the process in accordance with the invention.

Fig. 2 is a cross-section taken approximately on the line 2-2 in Fig. 1.

Figs. 3 and 4 are, together, a side elevation of the apparatus on a larger scale.

Fig. 5 is a side elevation on a still larger scale of a drum where the fiber material is coated with a binding agent, portions being broken away to show interior construction.

Figs. 6 and '7 are a bottom and end view, respectively, of the drum shown in Fig. 5.

Fig. 8 is a side elevation, partly in section, of conveyors and a picker roll for handling the fiber material.

Figs. 9, 10, 11 and 12 are, together, a side elevation on a larger scale of that portion of the apparatus that prepares and loads the pressing plates with a uniform layer of fiber material coated with a binding agent.

Figs. 13, 14, 15 and 16 constitute, together, a plan of the apparatus shown in Figs. 9 to 12.

Fig. 17 is a cross-section taken approximately on the line ll'l l in Fig. 9.

Fig. 18 is a cross-section of one form of a device for lubricating the pressing plates.

Fig. 19 is an enlarged cross-section of a dividing strip at the junction of two pressing plates.

Fig. 20 is a horizontal section taken approximately on the line 2@2B in Fig. 19.

Fig. 21 is a schematic plan on a smaller scale, showing the position of the dividing strip with respect to the pressing plates.

Figs. 22, 23 and 24 are cross-sections similar to Fig. 19 but showing alternative constructions.

Fig. 25 is an end elevation of one of the picker rolls shown in Fig. 10.

Fig. 26 is an end elevation of one of the combing or leveling rolls shown in Fig. 11.

Fig. 27 is a cross-section taken approximately on the line 27-4? in Fig. 12.

Fig. 28 is a cross-section taken approximately on the line 28-28 in Fig. 12.

Fig. 29 is an enlarged partial cross-section, showing one of the sets of rollers for guiding and supporting the pressing plates during the loading cycle.

Fig. 3G is a schematic longitudinal section illustrating the loading of the pressing plates.

Fig. 31 is a schematic cross-section showing a plurality of plates in a press with layers of material between successive plates.

Fig. 32 is a plan of the parts shown in Fig. 31 with the upper plates and upper press member removed.

Figs. 33 and 34 are a cross-section and plan, respectively, corresponding to Figs. 31 and 32 but with the parts shown in the positions they would occupy after the material has been compressed.

Fig. 35 is an end elevation showing in more detail a press for compressing the slabs of material.

Fig. 36 is a side elevation of the press shown in Fig. 35.

Fig. 37 is a plan of the press.

Fig. 38 is a schematic vertical section, showing another kind of press designed for continuous operation.

Fig. 39 is a plan of the press shown in Fig. 38. The plant shown schematically in Figs. 1 and 2 of the drawings comprises an excelsior-preparing and treating section A where the excelsior is prepared and is coated with a binding agent, a plate-loading section B where a layer of coated excelsior is deposited on pressing plates while the latter are continuously adr.

vanced and a pressing section C where the layer of coated material is subjected to pressure to compact it in all directions.

The excelsior is produced by one or more planers i (Fig. 2) and cut into predetermined lengths by a cutter 2. The length of the strands of excelsior should be not less than one inch or more than six inches and, preferably, should be about three or four inches. The cut excelsior is blown through a conveyor pipe 3 into a bin 4 from where it is fed by cooperating conveyors 5 and t and a rotating picker roll I (Fig. 4) onto a sloping conveyor 8. The conveyors 6 and 8, as well as other conveyors for carrying the excelsior, preferably comprise a plurality of transversely extending plates Q carried by spaced chains ill, each of the plates having an upwardly ofiset lip l l which projects over the edge of the adjacent plates. The picker roll i (Fig. 8) comprises a plurality of rows of spikes l2 1 inder 23 (Figs. 5 to '7).

mounted on a suitable base or cylinder is and rotates in the direction of the arrow so as to strew a uniform layer of excelsior on the conveyor 8.

While traveling on the conveyor 8, the excelsior is moistened by liquid from a plurality of spray heads I5 (Figs. 1 and 4) supplied by a pump 58 from a tank ll (Fig. 4). Excess liquid drains off through the conveyor and is collected by an apron it which returns it to the tank IT. A reservoir i9 supplies additional fresh liquid to the tank. If Portland cement is to be used as the binding agent, the liquid used for moistening the excelsior be water or a weak aqueous solution. It is preferred to use a 2 to 5 Baum solution of calcium chloride. The dry Weight of the calcium chloride used should be 1 72 to 3% and, preferably, about 2% of the weight of dry cement to be used as the binding agent.

A. picker roll 2! discharges the material in a loose condition from the conveyor 8 into a hopper-like chute 22 which guides it into the upper end of an inclined open-ended rotating cyl- The cylinder 23 is rotatably supported by spaced rollers Z l which are provided on spaced parallel shafts 25 and engage ribs or bands 25 provided on the cylinder. A roller 21 engages the lower side of one of the ribs 26 to take axial thrust resulting from the inclination of the cylinder and to keep the ribs 26 in alignment with the rollers The shafts 25 are driven by chains 28 from a power shaft 2:? and, in turn, drive the cylinder or drum 23 through the engagement of the rollers 2 3 with the ribs 26 of the drum.

A rotatable shaft 3b extends lengthwise through the open-ended drum 23 and carries a multiplicity of fingers or paddles 3i which are of such length that they come fairly close to, but do not engage, the inner surface of the drum. The shaft is eccentric of the drum and is driven in the direction indicated by the arrow in 7, for example by means of V-belts 32 (Fig. 5). The speed of rotation of the shaft 31} is greater than that of the drum 23. For example, the shaft 30 may be rotated at 300 to 508 R. P. M. While the drum 23 is rotated at a speed of 15 to 30 R. P. M. As a result of this rotation, the wet excelsior fed into the upper end of the drum 23 is tumbled and tossed and thoroughly mixed as it travels by gravity down through the drum.

The binding agent in dry powdered form, for example Portland cement, is lifted by a conveyor 34 into a bin 35 from which it is fed by a screw conveyor as into the upper end of the rotating drum 23. The conveyor it enters the upper end of the drum 23 just above the center and to one side of the chute 22. An air blower 3? (Fig. 3) discharges a blast of air just below the discharge end of the conveyor 3% to blow the cement into the rotating drum and distribute it uniformly throughout the tumbling and tossing mass of excelsior in the drum. The cement adheres to the wet excelsior and forms a uniform coating on strand. The wetness of the excelsicr entering the drum 23 is precisely controlled to provide just enough moisture to form a cement coating on the strands of excelsior of proper consistency for maximum bonding power and strength. The addition of further water after the excelsior has been coated with cement is avoided as it would tend to wash off the cement from the excelsior.

At the lower end of the drum 23, the cementcoated excelsior is discharged onto a conveyor 38, 

